If you’re aiming to reduce heat stress in your warehouse or commercial premises, an industrial cooler is an efficient, cost-effective solution. These systems – particularly evaporative models – can significantly lower indoor temperatures, improving working conditions for your staff. But to ensure long-term performance, regular maintenance is essential.
This practical guide covers everything you need to know to keep your industrial air cooler operating at peak efficiency year after year.
Why Industrial Cooler Maintenance Matters
Proper maintenance doesn’t just protect your equipment – it maximises cooling efficiency, extends system lifespan, and prevents costly breakdowns. With just 30 minutes of care each month (or less, depending on the environment), you can ensure your industrial cooler runs smoothly all season long.
Maintenance Schedule: How Often Should You Service an Industrial Cooler?
The frequency of regular maintenance for your industrial cooler varies based on how and where it’s used. In dusty or harsh environments, monthly servicing is recommended, while in cleaner settings, annual maintenance may be sufficient. Each maintenance session typically takes about 30 minutes. Conducting a monthly inspection of key components helps determine if more frequent servicing is needed.
When preparing the cooler for end-of-season storage, cleaning usually takes around one hour in a clean environment, but can extend to two or three hours in dustier conditions. Additionally, a three-hour idle run is necessary to fully complete the maintenance process.
Periodic maintenance for Industrial Coolers: the steps to follow
Maintenance of side air filters
Air filters are critical for keeping dust and pollutants from clogging the honeycomb cooling pads. In polluted environments, clean them monthly. In cleaner spaces, annual cleaning is often enough.
Cleaning is quick and easy, and takes just 10 minutes: all you have to do is remove the dust dry, then rinse with water.
Maintain the Honeycomb Cooling Panel
The honeycomb panel is the key component of evaporative cooling in an adiabatic industrial cooler. With proper preventive maintenance, these panels can last over three years. Maintaining them is crucial to preserving the cooler’s performance, which can be affected over time by two main issues.
The cooling water contains minerals, while the evaporated water is pure. During evaporation, minerals – especially calcium – precipitate out. When combined with CO₂ in the air, calcium forms limescale deposits around the honeycomb panel’s pores. These deposits gradually block the contact between air and water, reducing evaporation efficiency and lowering the cooler’s overall performance. Installing a demineralising filter upstream is an effective way to minimise this limescale buildup.
Drain and Clean the Water Tank
As water flows through the system, it carries dust and mineral deposits – especially limescale – from the honeycomb panel down to the bottom of the tank. Over time, these residues build up and form sludge. If left untreated, this sludge can clog or damage the pump, disrupting the smooth operation of your industrial cooler.
To prevent this, it’s essential to regularly drain and clean the water tank. Perform this cleaning as soon as you notice sludge beginning to form. Maintenance is straightforward: a mixture of water and household vinegar works effectively to remove buildup and keep the tank in good condition.
Inspecting Components: Preventive Checks and Troubleshooting Your Industrial Cooler
If your industrial cooler isn’t performing at full capacity, one or more components may be faulty. You can check the key parts yourself or consult a technician for a detailed diagnosis.
Here’s what to inspect:
- Air circuit: Ensure the fan is running at full speed. Reduced airflow often indicates clogged air filters or dirty evaporative panels.
- Water circuit: Verify that water is evenly distributed to the cooling panels. Issues here might stem from a faulty pump, leaks in the system, or incorrect water levels.
Pump failure is a common cause of poor performance. It can result from sludge being drawn into the pump or from dry running. In dry running cases, the sensors that monitor the pump’s water immersion may become clogged with mud and stop functioning correctly. Additionally, if the cooler isn’t positioned level, the sensor might falsely detect sufficient water when the pump is actually dry, potentially causing long-term pump damage.
End-of-Season Maintenance: Keep Your Industrial Cooler Running Smoothly
To ensure your industrial cooler operates efficiently year after year, it’s important to perform annual preventive maintenance at the end of each season before storing it clean and dry. This process typically takes about an hour in clean environments, but can take several hours in dustier or more polluted conditions.
The annual maintenance routine includes:
- Removing and thoroughly cleaning the honeycomb cooling panel.
- Draining and cleaning the water tank and internal walls. Use a mild acid like vinegar to remove any limescale buildup if necessary.
- Deep cleaning the pump strainer, pump, and water level sensors.
- Reinstalling the honeycomb panel and running the unit in free cooling mode for three hours to fully dry the system. This step is crucial to prevent mould growth caused by stagnant water during storage.
- Finally, store the cooler in a dry, protected location.
Following this routine will have your industrial cooler ready and reliable for the next season.
Final Thoughts: The Importance of Maintaining Your Industrial Cooler
Investing just a small amount of time each month keeps your industrial air cooler running efficiently and reliably. Whether you’re using a fixed or mobile industrial cooler, maintenance is straightforward and requires minimal effort – often less than 30 minutes per month.
Keeping your equipment in top condition helps create a safer, more comfortable environment for staff and customers alike.
Need help with cooler maintenance or looking to hire an industrial cooler? McCarthy Hire is your trusted partner for high-performance cooling solutions and expert support.
Call us on 01604 635333 or email us at [email protected] today to discuss.